WO2011055350A1

WO2011055350A1 - Bleach safe, stain free, quick drying drylon rugs

Info

Publication number: WO2011055350A1
Application number: PCT/IB2010/055068
Authority: WO
Inventors: Rajesh Rameshkumar Mandawewala
Original assignee: Rajesh Rameshkumar Mandawewala
Priority date: 2009-11-09
Filing date: 2010-11-08
Publication date: 2011-05-12

Abstract

A process for making a Drylon rug is disclosed, wherein the said process comprises use of dope dyed, micro-denier filament, cabled and heal set polyester yarn or micro denier filament, cabled heat set dyed with antimicrobial treatment for tufting of rugs, thereby eliminating the process of batch dyeing after the formation of rugs and further ensuring that the rugs are bleach safe, quick drying, anti microbial and stain resistant. The present indention also discloses, Dry Ion rugs as manufactured using yams of invention. Further, the πresent invention discloses the process for manufacture of Drylon Yarms.

Description

BLEACH SAFE, STAIN FREE. QUICK DRYING DRYLON RUGS

FIELD OF THE INVENTION:

{0001 i The present invention relates to rugs and rug manufacturing. More particularly, the present invention relates to process for manufacturing rugs that comprise of tufted, dope- dyed, micro-denier per filament, cabled and heal set polyester yarn and'Or micro- denier per filament, cabled, heat set, yarn dyed polyester yarn with antimicrobial treatment thereby incu lcating properties of bleach fastness, stain resistance and quick drying. Rugs manufactured thereof are also covered, further, the invention covers the process for manufacturing of the DRYLON yarns.

BACKGROUND OF THE INVENTION:

[0002 j Rugs are thick woven floor mats of shaggy or thick piled surface. Rugs are tufted floor covering used in specific areas of application. Rugs may have thick piles on one or both sides of the backing fabric. The thick. iled surface is also sheared to give the surface soft velvety touch.

[00031 Ru s in ay have tufting on one surface and latex or rubber coating on the other surface to hold the tufts in place; as otherwise the tufts may get dislodged irom the backing fabric. Further, the latex or rubber coating acts as anti-skid surface. s 0004] Rugs are formed with a backing fabric and pile yarns for tufting. The backing fabric is normaliy a cotton canvas or High Density Poly Ethylene (HDPE) or polypropylene (PP), with or without Nylon fleece, woven fabric or non-woven fabric of polypropylene fibers,

[OOOSj The pile yarns are usually selected from natural fiber yarns, such as cotton, linen, hemp, sisal, wool, silk, ramie, banana fiber, or regenerated cellulose fiber yarns, such as viscose, bamboo, modal rose or synthetic fiber yarns, such as nylon, polyester and polypropylene. {0006] Commercially available polyester yarns are known by various names such as, RECRON^®, TERYLE E^®, TERENE™, DACRON^®, and TETRON™. The normal polyester filaments for rugs are produced in micro deniers, viz. 1 ,0; 1.2; 1.3 etc., and arc dyed after rugs arc tufted. These batch-dyed rags are not fast to bleaching as the dyes are not deeply penetrated inside the fiber structure, aa the dye is applied externally to the tufts of^" rugs.

[0007] During the course of the explorations of the various polyester filaments available for usage in the tufting of the rugs, it was noticed that dope dyed, micro-denier, cabled and heat set polyester yarn and/or micro-denier per filament, cabled, heat se , yarn dyed antimicrobial treated polyester yarn were not at all available or used. Commercially, only bright micro-multlfiiament polyester yarns are available, for use in tufting and the rugs in batch process with dispersed dyes or cationic dyes. The batch dyeing results in surface penetration, whereby the dyes are vulnerable to bleach and to bleeding or staining during wet or dry washing.

|0008} With a view of inducing bleach fastness and preventing bleeding or staining of dyes, Fujita, Masashi et «/. introduced rugs made of polyester fibers, which have a supple and soft hand, further, the rugs of said invention are fast to dyeing and possess excellent durability. The inventors have filed a Japanese Patent Application No. JP9084685, which covers the above stated invention. However, the patent does not teach use of dope eyed micro-denier filament, with master batch dyeing during extrusion, cabled heat set polyester filament yam and/or micro-denier per filament, cabled, heat set, yam dyed with antimicrobial treatment, polyester yarn in manufacture of bleach fast, stain resistant, antimicrobial and bulky rugs.

[0009} In view of above, the inventors propose to introduce a novel rug, named as DRYLO^'N rugs, which are made using novel fibers which are dope dyed, micro-denier per filament, cabled and heat set polyester yarns and'or micro-denier per filament, cabled, heat set, yarn dyed polyester yarn with antimicrobial treatment, named as DRY tON yarn. SUMMARY OF THE INVENTION:

[0010] In view of above, the main object of the invention is to provide a process for manufacturing of bleach safe, quick drying, stain resistant DRYLON rugs using dope-dyed, micro-denier per filament, cabled, heat set polyester yarn and/or micro-denier per filament, cabled, heat set, yarn dyed polyester yarn with antimicrobial treatment, in tufting of D YLON rugs, thus eliminating the process of batch dyeing after formation of rugs.

BRIEF DESCRIPTION OF DRAWINGS:

[00 S 1 Fig. 1 depicts a flowchart for process for production of DRYLON rugs using a table tufting procedure. 0012] Fig. 2 depicts a flowchart for process for production of DRYLON rugs using a machine tufting procedure.

{0013} The invention will now be described in detail, along with certain preferred and optional embodiments so that various aspects thereof may be more fully understood and appreciated.

(0014J The current invention relates to use of dope dyed, micro-denier per filament, cabled and heat set polyester yarn and/or micro-denier per filament, cabled, heat set , yarn dyed polyester yarn with antimicrobial treatment, for tufting of rugs that are bleach safe, stain resistant and quick drying.

[0 15] For the purpose of this invention, the terms '"DRYLON," "DRYLON fiber," '^•DRYLON yarn, DRYLON tufting yarn" relate to a heat set, cabled polyester yarn which comprises polyester filaments, called "DRYLON filament." which are dope dyed by adding colour master batch during the melt-spinning and extrusion or yarn dyed in pressure vessels, thereby inculcating properties of fastness to bleaching, wet and dry rubbing, washing and light. Such kind of micro-denier per filament, dope dyed, cabled and heat set van- and micro-denser per filament, cabled, heat set, yarn dyed antimicrobial treated polyester yam, is specially made for this purpose and is not commercially available and is not disclosed in prior art. The DRYLON yam as above, wherein heat setting is carried cat in saturated steam.

[0016j For the purpose of this invention, the term "'DRYLON rug" or "rug" reiaies to a rug formed by use of DRYLON filaments, as defined above.

(0017 J It must be noted that as used herein and in the appended claims, the singular forms "a," "an," and "the" include piural reference unless the context cleariy dictates otherwise.

[0018] it is understood that the disclosed invention is not limited to the particular methodology, protocols, and reagents described as these may vary, it is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to limit the scope of the present Invention, which wli! be limited only by the appended claims.

|00!9j Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the appended claims.

[0020] Unless defined otherwise, all technical and scientific terms used herein have the same mean ings as commonly understood by one of skill in the art to which the disclosed Invention belongs.

[0021] The DRYLON yarns used for manufacturing the rug of invention have micro- deniers like 1.0, 1.2, 1 .3 but are dope dyed and/or yarn dyed after cabling and hea setting. Dope dyeing gives an opportunity to color dye to bind firmiy to the filament structure. The yam dyeing after cabling and heat setting likewise enables dye penetration thereby prevents bleeding or fading or staining of dye. Surface presence of dye, makes dye easily washable, which results in bleeding or fading or staining of color. |00221 The polyester filaments of instant invention are made from polyester chips (polyethyleneterephalate) of particular master batch, and dosing is carried out with mono- colour dyes during melt spinning. After melt spinning (by adding master batch during extrusion) of the required micro-denier raono-filament, the extruded filaments are then cabled to requisite denier, (for example, 2400 filaments of 1 .0 denier mono-filament) on the twisting machine, heat set in saturated steam and wound on cheeses, to yield dope- dyed, micro-denier per filament, cabled yarn. As such, the use of dope dyed yarn eliminates the need of further dyeing of the finished product. In the case of yarn dyed DRYLON filament, the dyeing is carried out in pressure vessels, after the filaments are cabled and heat set.

[0023] The use of DRYLON yarns imparts certain properties to the rug, primarily bleach safe, that is, the rug is resistant to ail kinds of bleaches used during domestic and industrial washing. Use of DRYLON tufting yarn makes the finished product a stain free product, that is, the rug does not retain stains of any kind and also inculcates quick drying property to rug.

{0024] The DRYLON filament is dope dyed by adding color master batch during the melt spinning and extrusion and hence the colors are fast to light, wet and dry rubbing, washing. Further, since the dyeing takes place during melt-spinning of the filament yarn, the dye forms integral bonds firmly with the filament structure, thereby imparting bleach fast property to filament, and rug as such.

[0025] Similarly in the case of yarn dyeing the dyeing takes place after cabling and heat setting, in the pressure vessels under set process parameters, which ensure internal bonding of the dyes with the filament, thereby imparting bleach fast property in to the subsequent rug made out of it.

{0026] As far as the instant invention is concerned, the fastness to bleaching is property of the dope dyed, micro-denier, cabled and heat set polyester yarn and micro-denier per fi lament, cabled, heat set, yarn dyed, antimicrobial treated polyester yam, has been exploited by exploring the possibilities of introducing DRYLON in the tufting of the rugs.

3 [00271 The DRYLON filament as per this invention has deniers in range of i .0, i .2, 13, Till 5.0 PF that are dope dyed. As dye is incorporated at the time of melt-spinning, the dye forms bonds with the filament structure and as a result the dye is firmly embedded in the fi lament.

[0028} In the case of yarn dyed DRYLON filament, this invention has deniers in range of 1 .0, i 1 ,3, till 5.0 DPF, the dyeing is carried out in pressure vessels, after the filaments are cabled and ^'neat set.

[0029] In an embodiment, the invention provides a process for production of DRYLON rugs comprising three stages. The first stage is tufting wherein, the backing fabric is creeled on to the machine at the back of the needle head and threaded up to the bed, where actual tufting by the needles is carried out, A requisite number of DRYLON (either dope dyed or yarn dyed) cheeses are creeled on to the creel of the Ail Loop Machine (ALP), Multi Loop Cut Level Machine (MLCL) , or All Cut Pile Machine (ACP) machines. The yarn from the cheeses is threaded through the tubing and tufting needles of the machine as per design pattern fed in to the computer of the machine and tufting operation starts.

[0030] The second stage is coating, wherein the tufted roil from the tufting step is loaded on to the latex coating machine, where the coating is a continuous operation, The supply of mixture of foam latex, accelerator and gel is through automated system. The thickness of the coat an i controlling of the GSM (g m²) is done through microprocessor based programs. The embossing of the !atex backing to introduce anti-skid property and baking and drying of latex are carried out by system itsel f.

[0031 { The third stage is cutting, wherein cutting of the tufted and coated rug fabric is carried out on the automatic infra red guided cutting machine to the requisite size as per the specifications.

[0032] The cut and coated rugs are further stitched on four sides on stitching machines with folders for guiding the piping cloth or all the four sides are over locked with the DRYLON yarn instead of piping cloth. The stitched rugs are then washed, checked. mended, folded, passed through needle detectors, and packed in to poly bags before packing in to cartons. 0 33] The machine as used for production of DRYLON rags of instant invention is selected from an All Loop Machine (ALP), a Multi Loop Cut Level Machine (MLCL), or an Λϋ Cut Pile Machine (ACP)

[0O34| An All Loop (ALP) Machine having gauge of 3/16 Inch or 3/S inch, resulting in production of iinear loops with the capability to have loop densities in range of 16 to 80 per sq. inch and capable of introducing pile heights of 3mm to 34 mm, can be employed for manufacturing the rag of invention. The creei capacity of the said machine is 1 728 cheeses

[0035] A MiilH Loop Cut Level Machine (MLCL) having gauge of 1/8 inch, resulting in production of linear loops, with capability to have loop densities in range of 20 io 80 per sq. inch and loop height of 3 to 20mm arid cut pile height of 4 to 22 mm, can be employed for manufacturing the rug of invention. The creel capacity of the said machine is 2592 cheeses. 0036] An Ail Cut Pile Machine (ACP) having 1 /8" gauge, capable of introducing pile height from 3mm to 34mm. with possible pile density of 20 io96 per sq. inch can be employed for manufacturing the rug of invention. The creel capacity of said machine is 2592 cheeses.

[0037] An All Cut Pile Machine (ACP) having 3/1 6 inch gauge, capable of Introducing pile height from 3 to 34 mm and density of 1 8 to 88 per sq. inch can be employed for manufacturing the rug of invention. The creel capacity of said machine is 1728 cheeses.

| 038j A Tabie-Tyfiirrg Machine, having a gauge of 3/16 inch, which Is capable of introducing pile height of 3mm to 30 mm and a pile density of I S to 53 per sq. inch, can be employed for manufacturing the rug of invention. The creei capacity of said machine is 8 cheeses. In case citable tufting, the tufting is done on the pre-st itched (piped) backing of the requisite size, the tufted rug is washed, carved and spray latex coated instead of machine latexlng. [603 j in another embodiment, the invention provides for the DRYLON rugs as manufactured by the above mentioned process.

[0040] in a preferred embodiment, a process for making a DRYLON rug comprising use of. dope dyed, micro denier, cabled and heat set polyester yam or micro denier per filament, cabled, heat set. yam dyed, antimicrobial treated polyester yarn, for tufting of rugs, thereby eliminat ing the process of batch dyeing after the formation of rugs, further ensuring thai the rugs are bleach safe, quick drying and stain resistant wherein, said process comprises following steps:

(a) tufting of micro-denier, dope dyed, cabled and heat-set polyester filament, or micro denier per filament, cabled, heat set . yarn dyed, antim icrobial treated polyester yarn, on cheeses is creeled on tufting machine to form tufted fabric roll;

(b) loading the tufted roils of step (a) on !atex coating machine, followed by application of latex to form a rug fabric;

(c) cutting the rug fabric of step (b) on a infra-red guided cutting machine as per pre-determined specification to form rugs;

(d) stitching of rugs of step (c) on four sides by stitching machine;

(e) washing, checking, mending, and folding and packing the stitched rugs of step (d), in poiy bags, and;

(0 packing the packed rugs of step (e) in cartons.

[00 1 j The process for making DRYLON rugs as above, wherein the dope dyed, micro denier per filament, is in range of 1.0 to 5.0 DPF and with filaments of 600X2, 1200X2, 1 800 and 2400 filaments; up on cabling wherein, the range is from 150 to 3600 filaments or 75x2 to 1 800x2. The DRYLON filaments as used in process are dope dyed during the process of filament extrusion and the dope dyeing is carried out by adding color master batch during extrusion of spinning process. The dope dyed filaments impart bleach safe and good color fastness to the said rug.

[0042] The process for making DRYLON rug as above, wherein, the micro-denier per filament, is in range of i .O to 10 DPF and with filaments of 600X2, 1200X2, 1 800 and 2400 fi laments, up on cabling wherein, the range is from 1 50 to 3600 fsiaments or 75x2 to 1 800x2 are heat set and dyed in pressure vessels. The DRYLON filaments as used in process are yarn dyed after the process of extrusion, cabling and heat setting. The yarn dyed filaments impart bleach safe and good coior fastness to the said rug.

[0043] DRYLON yarns of instant invention have a multifilament configuration that results in soft and bulky tufts. The tufting is carried out on table-tufring or machine tufting. The height of tufting loop is adjusted in range of 3mm to 34mm and tufting loop density is adjusted in range of 18 to 96 per sq. inch. In case, machine tufting is carried out it includes jacquard patterning.

[0044] The process for making DRYLON rugs as described above further includes coating of the rugs with latex on remote side to impart anti-skid property and to hold the tufts intact. The iaiexing is carried out on continuous latexing machine, wherein iatexing mixture comprises of synthetic or natural latex, accelerator and gel. in case, rug is tufted on table, iatexing is carried out by spray coatin or brush application on one i.e. remote side of rug.

Examples:

{^'0045J With reference to above specification the instant invention is exemplified by following example.

EXAMPLE 1

[0046] A DRYLON rug made of DRYLON yam which has properties of bleach fastness, stair; resistance and quick drying. The DRYLON tufting yarn is B . S. Blue colored, dope dyed 1.0 micro denier per filament fiber, which is further twisted with 900x2, micro filament to form 1 800 (900x2) denier tufting yarn.

[0047] The process for making the rug of instant invention comprises of tufting of 1 .0 DPF * 900*2 B. S. blue dope dyed filament creeled on 1280 cheeses to form, tufted fabric roll. The tufted roils are further loaded on latex coating machine followed by application o f latex a 20.0 Qz/sq. yard or 687 GSM to form a rug fabric. The latex coated tuft roils are cut on infra-red guided cutting machine as per pre-determined specification fed in the computer to form rugs. Lastly the rugs are stitched on four sides on a stitching machine and finally, the stitched rugs are then, washed, checked, mended folded, passed through needle detectors and packed in to poly bags before packing in to cartons,

10048} Tufting machine used for production of rugs as described in Example 1 is a muiii loop cut ieve! machine capable of producing jacquard design. The machine gauge of machine was set at 1/8 inch, thus producing 8 linear loops, with a capability to have loop density of around 20 to 80 per sq, inch, for purpose of this example loop density is set at 64 per sq. inch (8 stitches per inch 8 linear loops). 1280 cheeses of 1.0 micro DPF ^χ 1800 filaments {900x2} are used.

10049] The table below describes the technical specifications of Drylon rug, having a dimension of^* 20" ^x 30".

able i :

Sr. No. Description

TUFTING

I . Design iS

Type of tufting Machine | LCL

3. Tuft yarn 900x2

Drvlonl .ODPF, 1 80 TPM

4. Dope dyed color B.S Blue

5. Backing fabric 108 GSM

Polypropylene wove; backing(PP)

6. Coating 20 Oz/Sq. Yd Latex back

7. Tufting width 160 Inch 406.4 Cms

■ 8. Tuft yarn 24 Ozs/Sq.yd 813.6 GS

9. Backing width 168 inch 426.72 Cms

10. Backing weight 3.2 o¾ Sq. Yd 108.42 GSM

1 1. Length 39.37 Inch 100 eras

12. Tufted Rug weight 27.2 Oz/^'Sq.yu 922.04 GSM

1 3. Grey Wt/100 linier 374733.31

meters gm/l OOlinier

meters

COATING

14. Coating Weight 20.0 Oz/Sq.yc 678 GSM

1 5. Coated ru weight 47.2 Gz/Sq.ye 1600.08 GSM

J 6. Coated rug Wt/100 650272.51

ii iser meters gm/l O linier

meters

! 7. Liquid coating 405204 gms/100

Consisting of linier meter

92,4% foam

Latex.,4%

accelerator and

3.6% gel

CUTTING

18. Grey width 19.75 inches 50. 16 Cms

19. Finished rug Ί 9.25 inches | 48.89 Cms

width

20. Grey length 31 inches | 78.74 cms

21 . Finished rug 30.0 inches j 76.2 cms

leiiclh

22. Grey 47.2 Ozs 1600.08 GSM

OZSYD/GSM

23. Finished 46.96 Ozs 1 591.94 GSM

OZSYD/GSM

24. Piping/Rug 4.50 gms

25. Piping/100 Linier 4542.5? gms

meter

EXAMPLE 2

[0050] The following Table 2 details the physical and chemical properties of DRYLON yam oH .O to 10.0 denier per filament.

Table 2:

EXAMPLE 3 6051 ] A D YLON rug made of DRYLON yarn which has properties of bleach fastness, stain resistance and quick drying. The DRY LON tufting yarn is yarn dyed W. Denim shade, consisting of 1.0 micro denier per filament fiber, which is further twisted with 900x2, micro filament to form 1 800 (900^2) denier tufting yarn and dyed.

[6β52| Dyeing process for yarn dyeing is as below in Table 3. Dyeing of 1800/180tpm and 1 800/100 tpm of Semi Dull and Bright luster yarn. The dyeing is done at 132°C and the rate of raising temperature is not more than LOT) /min.

Table 3:

Steps Details

Setting Dyebath Se Machine with water at 50°C to 60°C

Adding Chem icals A id dispersing agent 0.5 TO ! GPL

Add leveling agent 0.5 TO ί GPL

Adjust the pH to 4.5 TO 5 with buffer.

Adding Dyes Add sieved dispersion dyes

Raising temp. Raise the temperature up to 132^aC.

Continue Dyeing At 132 ° C hold 30 minute.

Then drain at 132 ^g C

Reduction Clearing Reduction clearing with: Caustic soda and Sodiun hydrosulflte

For optimum fastness in ail except pale shades t e rednetior dealing is necessary

Neutralization.

[0053] Ants microbial treatment: - For this treatment use Heiq AGS-20 TF dosing is 1.5% to 2.5% on weight of material. Maintain the pH: .5 at room temp; run for 20-30min. Before giving this treatment give the 2-3 rinse. (Do not rinse the material after give the treatment of Heiq AGS-20 TF). [0054] Dyeing Process of Shade (NO. G3291 ) W.Denim, Denier;- 1800/1 80.

DYES RECIPE:

0.4620 FORON NAVY HWF

0.1 10 FO ON GOLDEN YELLOW SWF

0.0250 FORON RUBINE SWT

CHEMICAL USED:

1 GPL ACETIC ACID

i GPL LYOGE DFT

0.5 GPL SiTAMOL WS

1 GPL HYDRO & CAUSTIC

[0055! Maintain the pH 4 to 4.5 and the rate of raising the temperature at 1.0 C /mm, as see in Table 4 below.

Table 4:

Steps Details

Setting Dyebatn Set Machine with water at 50°C to 60°C

Adding Dyes Add sieved dispersion dyes

Raising temp. Raise the temperature up to 132°C .

Continue Dyeing At ! 32 ° C hold 30 minute.

Then drain at 1 32 ⁰ C

Reduction Clearing Reduction clearing with: Caustic soda and Sodiun hydrosulfite

Neutralization. 00561 The process for making the rug of instant invention comprises of tufting of 1.0 DPP X 900X2 W Denim yarn dyed filament, creeled on 1280 cheeses to form tufted fabric roll. The tufted rolls are further loaded on latex coating machine followed by appl ication of latex at 20.0 Oz sq. yard or 687 GSM to form a rug fabric. The latex coated tuft rolls are cut on infra-red guided cutting machine as per pre-determmed specification fed in the computer to form rugs. Lastly the rugs are stitched on four sides on a stitching machine and finally, the stitched rugs are then, washed, checked, mended folded, passed through needle detectors and packed in to po!y bags before packing In to cartons.

(0057] The tufting machine used for production of rugs as described in Example 3 is a multi loop cut level machine capable of producing jacquard design. The machine gauge of machine was set at 1/8 inch, thus producing 8 linear loops, with a capability to have loop density of around 20 to 80 per sq. inch, for purpose of this example loop densi ty is sei at 64 per sq. inch (8 stitches per inch ^■< 8 linear loops). 1280 cheeses of 1 .0 micro DPF 1 800 11 laments (900*2) are used.

[ 58f The table below describes the technical specifications of DRYLON rug, having a dimension of 20" X 30"

Table 5:

Sr. No. Description

1. Design RIB

Type 0 Machine MLCL tufting

3. Tuft yarn 900x2

Drylon i .ODPF, 1 S0 TPM

4. Yam dyet W.Denim

color

5. Backing 108 GSV fabric Polypropylene woven backmg(PP)

6. Coating 20 Oz Sq. Y<

Latex back

?. Tufting width 160 Inch 406.4 Cms

8. Tuft yarn 24 Ozs/Sq.vd 813.6 GSM

9. Backing 168 Inch 426.72 Cms

width

10. Backing 3.2 o2 Sq. Y 108.42 GSM

weight

1 1 . Length 39.37 Inch 100 cms

12. Tufted Ruj 27.2 922.04 GSM

weight Oz/Sq.yd

1 3. Grey Wt/ i OC 374733.31

linier meters gm/ί OOl inier meters

EXAMPLE 4 0059] The following table details the physical and chemical properties of Dryjon yarn of i .0 to 10.0 denier per filament

EXAMPLE 5

10060] Tests were conducted on the DRYLON Rug to assess its Bieach safe quality. {0061 ) Wash Test: DRYLON rugs were washed 50 times (50 wash and 50 drying cycles) with 8 OK of Bleach and detergent. As a result, the rugs with stood the washing and the color did not bleed, fade or stain.

(0062) State Test: DRYLON Rugs were smeared with Lipstick, Mascara, Iodine, Benzoyl Peroxide cream (10% Benzoyl Peroxide) marker ink (indelible Ink) and hair c!ye and washed with 8 oz of bleach and detergent. i^'0063| The result showed that all stains washed out, except the indel ible ink of marker pen.

[0064] Further the DRY LON rugs were washed for AATCC method 135/150 for 3 J 0 and 25 washes and the result on grey scale rating for color change and staining conformed to 4.0 under aii the wash conditions, indicating very high performance. The following table gives the details of tests conducted and the results observed.

Tabic 7:

[0065j The instant invention is more specifically explained by above examples. However, those skilled in the art will recognize or be able to ascertain, using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the examples and claims appended hereinafter. Ail patents and references cited herein are hereby incorporated in their entirety by reference.

Claims

I Claim:

1 . A process for making a Dry Ion rug comprising use of, dope dyed or yarn dyed, micro-denier per filament, cabled and heat set polyester yarn for Rifling of rugs, thereby eliminating the process of batch dyeing after the formation of rugs, further ensuring that the rugs are bleach safe, quick drying and stain resistant wherein, said process comprises:

(a) tufting of micro-denier per filament, dope dyed, cabled and heat-set polyester filament or tufting of micro denier per filament, cabled, heat set yarn dyed with anti-microbtal treatment on cheeses i s creeled on tufting machine to form tufted fabric roi l;

(b) loading the tufted roils of step (a) on iatexing machine followed by appiication of latex to form a coated rug Iabric:

(a) stitching of rags of step (c) on four sides by stitching machine;

(e) washing, checking, mending and folding and packing the stitched rugs of step (d), in poly bags, and;

(0 packing the poly bag packed rugs of step (e) in cartons.

2. A process for making Dryion rug as claimed in claim 1 , wherein the dope dyed or yam dyed, micro denier per filament, is in range of LO to 5.0 DFF and with yarns of 600X2, 1 200X2, i 800 and 2400 filaments, up on cabl ing, wherein range is from 150 to 3600 filaments or 75x2 to 1 800x2.

3. The process for making Dryiors rug as claimed in claim 2, wherein the Dry ion filament is dope dyed during the process of filament extrusion by adding color master hatch during extrusion of spinning process.

4. The process of making Dryion rug as claimed in claim 2. wherein the Drylon filament is dyed after cabling and heat setting in pressure vessels with antimicrobial treatment.

5. The process for making Drylon rug as claimed it; claim 3. wherein dope dyeing imparts bleach safe property and good color fastness to the said filament.

6. The process of making Drylon rug as claimed in claim 4. wherein yarn dyeing imparts bleach safe and anti microbial properties,

7. The process or making Drylon rug as claimed in claim 1 , wherein cabling results in soft and bulky tufts.

8. T he process for making Drylon rug as claimed in claim 1 , wherein tufting is carried out on tahlc-i fUng or machine tufting.

9. The process for making Drylon rug as claimed in claim 8, wherein the tufting loop height is in range of 3 mm to 34 mm.

10. The process for making Dryion rug as claimed in claims 8, wherein the tufting has a loop density in the range of 18 to 96 per square inch. i 1 , The process for snaking Drylon rug as claimed in clai m 8, wherein machine tufting also inc. hides jaequsrd patterning.

12. The process for making Drylon rug as claimed in claim i . wherein the rug is coated with latex on remote side to impart anti-skid property and to hold tufts intact. S 3. The process for making Dr ion rug as claimed in ciaim 12, wherein latexing on the remote side of the rug fabric is carried out on a continuous latexing machine.

14. The process for making Dryion rug as claimed in claim 1.2, wherein the latexing mixture comprises of synthetic or natural latex, accelerator and gel.

1 5. The process for making Dryion rug as claimed in ciaim 12, wherein the said rug, is made on table-tufting which has iatex spray coated or brush applied on remote side.

16. The Dryion rug as manufactured according to the process as claimed in ciaim 1 , comprising use of dope dyed, micro denier per fi lament, cabled and heat set polyester yarn or microfilament cabled, heat set and yam dyed with anti microbial treated yam for tufting of the Dryion rug, thereby eliminating the process of batch dyeing after formation of rugs, further ensuring that the Dryion rugs are bleach safe, quick drying and stain resistant.

1 7. ^'The Dryion rug as claimed in claim 16, wherein the dope dyed or yam dyed, micro denier per filament ranges f m 1 ,0 to 5.0 DPF and with filaments of 600X2, 1 200X2, 1800 and 2400 filaments, wherein the range is from 150 to 3600 fi laments or 75x2 to 1800x2.

18. The Dryion rug as claimed in claim 17, wherein the Dryion fi lament is dope dyed during the spinning and extrusion process by adding color master batch during extrusion of spinning process or yarn dyed with anti microbial treatment, in pressure vessels alter extrusion, cabling and heat setting.

19. The Dry!on rug as claimed in claim 1 8, whereby dope dyeing or yarn dyeing of microfilaments imparts bleach safe property and good color fastness to the said filament.

20. The Dryion rug as claimed in claim 17, wherein cabling results in soft and bulky tu s. 2 ) . The Dry ion rug as claimed in claim 16, wherein tufting is on table -tufting or machine tufting.

22. The Dryloa rug as claimed in claim 21, wherein tufting loop height is in the range of 3 mm to 34rnm.

23. The Drylon rug as claimed in claim 21 , wherein Culling loop density is in range of 1 8 to 96 per square inch,

24. The Drylon rug as claimed in claim 21 , wherein machine tufting is in jacquard pattern.

25. The Drylon rug as claimed in claim 16 wherein the said rug is coated with latex on remote side to impart anti-skid property and to hold tufts intact.

26. The Dry-Ion rug as claimed in claim 25, wherein !ate ing is carried out on a continuous iatexing machine.

27. The Drylon rug as claimed in claim 25, wherein the Iatexing mixture comprises of synthetic or natural latex, accelerator and gel.

28. The Drylon rug as claimed in claim 25, wherein the said rug is made on table tufting which has the iatex spray coat or brush appl ied on remote side.